CASE STUDY: NUMIKON, ZAGREB, CROATIA

NumikoN improves browNfield operatioNal safety aNd efficieNcy with iNtergraph® cadworx® fieldpipe™ professioNal aNd caesar ii® process equipment specialist produces as-built models supporting inspection, non-destructive testing, pipe stress analysis and creation of plant documentation

ideNtifyiNg goalsNumikon specializes in the calculation and analysis of mechanical, power and process

equipment and components, project engineering of process and power plants, pipe stress

analysis, pressure vessel design, as well as laser scanning and laser surveying.

Numikon’s customer, INA-Industrija nafte d.d., a leading oil exploration, production, refining

and marketing company in Croatia was looking for an efficient solution to create as-built

information for their Sisak refinery.

INA d.d. hired a consortium of three companies (Numikon d.o.o., TUV-Croatia d.o.o.,

KONZALT ING d.o.o.) for the project.

overcomiNg challeNgesExtensive asset documentation for the refinery existed, but there was uncertainty about

how accurate and complete it was. Furthermore, there was insufficient information about

the specifications of the piping and exact pipe routings throughout the refinery. This lack of

information was highly undesirable for safety, operational, and regulatory reasons.

INA therefore decided to have all of the piping in the refinery surveyed to create an accurate

and up-to-date 3D model, complete with information about the piping material grades,

wall thicknesses, topology etc. of the pipes, and document all of this on new isometric

drawings. This information could then be used to perform pipe stress analysis on critical

pipelines.

The survey had to be undertaken while the refinery was operating. Some of the piping

was difficult to access because of its location above ground, or because it was insulated.

In addition, the work had to be carried out to a tight deadline.

To save time and improve safety, Numikon proposed using:

• Leica total station for laser surveying and measurement of the plant

• Intergraph CADWorx fieldPipe Professional to create the 3D model

• Intergraph CADWorx Plant Professional for isometrics and data integration

FACTS AT A GLANCE Company: Numikon d.o.o.

Website: www.numikon.com

Description: Numikon provides a wide range of engineering and analysis services for the process and energy industries. One of their specialties is surveying plant piping, creating 3D piping models, testing the wall thickness and hardness of piping and integrating this information with the 3D models.

Employees: 20

Industry: Chemicals, oil & gas, power generation and marine

Country: Croatia

PRODUCTS USED:

• CADWorx fieldPipeTM Professional

• CADWorx® Plant Professional

• CAESAR II®

KEY BENEFITS:

• Laser scanning offered major time savings compared to manual surveys • Laser scanning avoided the need to work at height or near hazardous equipment • 3D Models linked to equipment database and stress analysis software

• Intergraph CAESAR II for stress analyzing the piping systems

Numikon first analyzed INA’s drawing specifications and

configured the Isogen component of CADWorx Plant Professional

to ensure that all the deliverables met the company’s drawing

standards, and completely fulfilled the customer’s requirements.

They also entered details of the equipment used at the refinery in a

database to support day-to-day plant operations and maintenance

activities.

.

realiZiNg resultsNumikon surveyed their part of Sisak refinery in 49 days. Using the

laser surveyed data they created all deliverables required by their

client, including:

• 3D models

• Piping isometrics

• Details of piping components (valves, pressure regulators, flanges,

supports, etc.)

• Tag and nameplate details

• Details of the equipment and connected piping

• Pipe stress analysis results (including required test pressure) and

pipe data (wall thickness, material properties, etc.)

These deliverables enable the owner operator to operate the plant

safely and efficiently and comply with all regulatory requirements.

The detailed as-built data also greatly facilitates maintenance and

plant expansion and modification.

Mario Aníc of Numikon explained “When we first started using the

Leica total station and Intergraph software the two companies

trained our staff. It took them about ten days to get up to speed

and start on their first project. We were particularly impressed by

the in-depth knowledge of the Intergraph and Leica people. On

the whole we estimate that our productivity has gone up by as

much as 640% (six times)! This productivity gain means that we

can minimize the on-site project time and maximize efficiency,

offering our customers a very attractive package.

moviNg forwardMr. Anic continues: “Currently we are the only company in our

region to offer this service based on laser surveying and the

Intergraph software in a full package together with non-destructive

materials testing, measurement and hardness and thickness

testing. That gives us a major advantage in a competitive market.”

“Currently we have four employees who use this equipment and

software and we are planning to recruit two more in the near future.

We are using CADWorx fieldPipe Professional for oil refineries, the

pharmaceutical industry, gas plants and other sectors. At present

we are working on similar technical documentation packages

for another four plants, again based on laser surveying and

Intergraph CADWorx 3D models.” Mr Anic summarizes.

Soon to be known as Hexagon Process, Power & Marine, Intergraph Process, Power & Marine is the leading global provider of engineering software for the design, construction and operation of plants, ships and offshore facilities.

Hexagon Process, Power & Marine is part of Hexagon (Nasdaq Stockholm: HEXA B; hexagon.com), a leading global provider of information technolo-gies that drive quality and productivity improvements across geospatial and industrial enterprise applications.

AboUT InTErgrAph proCESS, powEr & MArInE

© 2016 Intergraph Corporation. All rights reserved. Intergraph is part of Hexagon. Intergraph and the Intergraph logo are registered trademarks of Intergraph Corporation or its subsidiaries in the United States and in other countries. Other brands and product names are trademarks of their respective owners. 01/2016 PPM–NL–0378A–ENG

Isogen isometrics created from the 3D model with CADWorx Plant Professional.

Laser surveying in action at the Sisak refinery using a Leica Total Station.

A 3D model of the plant created in CADWorx Plant Professional (part of the Sisak refinery).